Insulated shipping bags

ABSTRACT

A collapsible insulated bag designed to allow items retained within an inner pouch thereof to remain within predetermined temperature ranges for predetermined periods of time and wherein the bags are designed to be easily compressed or compacted for storage or shipment to end users. The bags include at least an outer reflective layer, an intermediate open foam layer and the inner pouch layer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application forPatent, Ser. No. 60/907,932, filed Apr. 23, 2007, the entire contents ofwhich are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to the field of thermal containers primarilyused in the shipping or storage of goods, foodstuffs, samples and thelike items that must be maintained within predetermined temperatureranges for predetermined periods of time in order to ensure the safetyand quality of such items. More particularly, the invention is directedto collapsible insulated bags that are designed to allow items heldtherein to be maintain within predetermined temperatures, either hot orcold, for extended periods of time. The collapsible bags are ideal forlong distance shipment of perishable items such as foods, samples andmedical items, and may also be used for catering, take-out as well asfor traditional cooler functions.

2. Brief Description of the Prior Art

There are numerous industries wherein the safe transportation orshipment and storage of temperature sensitive products or samples iscritical to the preservation of the products or samples. Medicalsupplies, samples, transplants and the like must often be maintainedwithin controlled temperatures during periods of shipment from suppliersto users, providers to patients, and between operating facilities. Withthe popularity of online grocery shopping growing, there is also a needto improve upon insulated packaging for transporting goods such asfrozen foods from temperature controlled environments to theend-consumers. Frequently, delivered packages may have to be left forextended periods in less than optimal ambient conditions before aconsumer actually takes possession of the goods being shipped.

Currently, to maintain shipped items at optimal temperatures, optionshave been tried which include foam coolers, dry ice packs or boxes andinsulated storage bags. Each of these options comes with drawbacks,including limited lengths of time for maintaining goods or items atoptimal temperatures, environmental impact or safety concerns andincreased shipping cost to cover container weight and/or size or expressdeliveries.

Foam coolers combined with dry ice packs can, in some instances,effectively maintain items at optimal temperatures, However, their useis costly in both supply costs and excess shipping costs. In addition,foam coolers have a negative impact on the environment and the handlingof dry ice packs can raise safety concerns.

Dry ice packs have been used alone to ship and deliver perishable items.However, their ability to maintain optimal temperatures for extendedperiods of time while in a standard cardboard container is extremelypoor.

Other bags have been used for short term transportation of perishableitems. However, their use is limited to only conveyance of the item andnot for maintaining the item in an optimal temperature range for anysignificant period of time, such as more than one to three hours ormore.

In view of the foregoing, there is a need to provide insulated shippingcontainers that can provide greater insulating properties to ensure thatgoods, foodstuffs, medical supplies and samples and other items that aretemperature sensitive may be safely shipped and maintained withinnecessary temperatures for greater periods of time than is possibleusing conventional shipping containers.

There is a further need to provide insulated shipping and transportationcontainers that can also be compactly configured to reduce shipping andtransportation costs without reducing the insulating properties thereof.

SUMMARY OF THE INVENTION

The present invention includes flexible or collapsible hot/cold storageor shipping bags that are preferably self configuring and/or supportingbut easily manipulated to a reduced size to be placed in an outercontainer or box for shipment. In the preferred embodiments, the bagsare formed of at least three layers of insulating materials including anouter metallic or radiate energy reflecting layer, an intermediate opencell foam insulating layer and an inner low thermal convection and foodgrade plastic layer.

In some embodiments, the fully flexible insulated bags are designedto-be used as stand-alone containers capable of maintaining a supportingshape when placed on a support surface. However, the bags may also beplaced into, or folded and subsequently placed into, an outer protectivestructure such as a cardboard container or box, a plastic bag or bin orany other shipping container. Due to the flexible insulating materialsof the bags, they may be shaped to conform to, or reduce the spacedoccupied within, outer containers, thereby maximizing shippingefficiencies and reducing shipping costs.

In a preferred embodiment of the invention, the inner plastic layer isformed as a bag with an outwardly folded cuff at an opening therein suchthat the cuff frictionally receives and retains upper free end portionsof opposing side walls of the intermediate insulation material therein.In this manner, the intermediate insulation material is mechanicallysecured to the inner plastic layer such that both layers may besimultaneously inserted within the outer reflective or metallic foillayer. This frictional retention of the intermediate layer within thecuff of the inner plastic layer will also function to retain theintermediate insulating layer in place within the outer layer when thecomposite insulating bags of the invention are in use. In someembodiments, the upper end of the inner plastic bag layer is welded tothe inner surface of the outer layer, at or spaced slightly below theupper edges of the outer layer. The outer reflective or foil layer, isalso formed into a bag-like configuration by folding a length of foil onitself, from end-to-end, and thereafter welding the opposite side edgestogether.

The composite or multi-layer insulated bags of the invention may alsoinclude different closure and handle structures. In some embodiments,the inner plastic bag-like structures may be heat sealed at their upperopen ends after articles or items are placed with the insulated bags. Inother embodiments, mechanical zip-like closures or double sided tapesmay be used to seal the upper open ends of the inner plastic bags afterarticles or items are placed therein. In yet other embodiments, theinner plastic bags may not be sealed. Preferably, the upper ends of theouter reflective or foil bag-like layers are provided with either heatseals or mechanical zip-like or friction lock seals. In someembodiments, the seals may be created using friction lock engaginghandle members that are initially sealed to the upper edges of theopposing sides of the outer reflective or foil layer and which includecomponents that interlock with one another as the handle members arelocked together.

In some embodiments of the invention, to facilitate the compact handlingand/or folding of the multi-layered insulated shipping and storage bagsof the invention for shipment to wholesalers or end users for subsequentuse, the interior of the bags, and especially the intermediate open cellfoam layers are designed to be evacuated by the application of a partialvacuum. Such a vacuum may be applied to the bags through an openingbetween the outer reflective layer and the intermediate open cell foammaterial thereof by use of a vacuum tube or by placing the bags withinan enclosure under a reduced atmosphere or by physical compression ofthe bags. When the vacuum tube is withdrawn or the predetermined reducedpressure is obtained within the bags, the outer openings therein areclosed by removable adhesive patches or covers to prevent ambient airfrom entering the bags. When the bags have been at least partiallyevacuated so that air is removed from the open cell foam and frombetween the outer reflective layer and the foam, they are easily foldedinto compact configurations for storage or for shipment. When the bagsare to be used by an end user, the patches or covers are removed and thebags will automatically expand as ambient air enters the vacuum openingstherein. After the bags are inflated, the adhesive patches or covers maybe reapplied to prevent contaminants from entering the openings therein.In this regard, when the insulated shipping and storage bags are to beused to ship or store items that must remain sterile, the vacuumprocesses and inflating processes may take place within sterileenclosures.

The compact handling of the multi-layered insulated shipping and storagebags of the invention for storage or shipment to wholesalers or endusers for subsequent use may also be accomplished by placing one or moreinsulate bags within an outer plastic bag have one end with a sealableopening. Thereafter, the outer bag is mechanically collapsed to forcemost air out of the enclosed insulated shipping bags and the outer bagand the outer bag subsequently sealed. In some embodiments, a partialvacuum may be applied within the outer bag to reduce the pressuretherein and to reduce the volume of the overall package.

Further, in the embodiments wherein the intermediate foam layers areseated or sealed with their upper edge portions within the cuffs of theinner plastic layers and the cuffs sealed to the outer reflective layeror wherein the upper edges of the inner plastic layer are sealed to theouter reflective layer to isolate the foam layer there between from theambient environment, any reduction in pressure within the space betweenthe foam layers and the outer reflective layer will not affect thesterility of the inner surface of the inner plastic layer.

In addition to the use of the collapsible hot/cold thermal insulatedshipping and storage bags for foodstuffs, such as frozen foods or hotprepared food dishes, the bags are also ideal for other uses includingtransporting of medical items including medicine, blood, samples andorgans, and other products that must be retained within tightlycontrolled temperatures.

The collapsible hot/cold thermal insulated shipping and storage bags arecapable of maintaining perishable items at their optimal temperaturesfor extended periods of time. By way of example, the process of keepingitems cold while moving them from one area to another is known as coldchain. A cold chain is further defined as an uninterrupted series ofstorage and distribution activities that are used to maintain thetemperature of an item in a given range. The collapsible hot/coldinsulated shipping and storage bags of the invention allow items to beleft with the end-consumers where the items can be safely maintained attheir optimal temperatures, either hot or cold, for three or more hours.

In addition, the insulated shipping and storage bags of the inventionare designed to be both light-weight and flexible thereby allowing thebags to be compressed, folded and compactly placed in shippingcontainers without consuming space that may be used for shipping otheritems and thereby aiding in reduction of both shipping and storagecosts.

A further advantage of the insulated shipping and storage bags of theinvention is that the open celled foam intermediate layer also functionto cushion the contents of the bags, especially during transit and thusdamage to the contents of the bags is less likely than with other priorart shipping containers.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the invention will be had with reference tothe accompanying drawings wherein:

FIG. 1 is a top front perspective view of one embodiment of the presentinvention shown in an open position to receive an article or itemtherein;

FIG. 2 is a cross section taken along line 2-2 of FIG. 1 showing theinsulation layers of the thermal insulated shipping and storage bag;

FIG. 2A is the cross section view of FIG. 2 showing the insulatedshipping and storage bag in a free standing configuration;

FIG. 3 is a top front perspective view of the embodiment of theinvention shown in FIG. 1 with an article placed therein and showing howthe insulated shipping and storage bag is self-standing on a supportsurface;

FIG. 4 is a top plan view of the intermediate foam layer showing cutouts with slits therein to facilitate the free standing nature of theinsulated bag when is use;

FIG. 4A is the top plan view of FIG. 4 showing the intermediate foamlayer in a folded configuration to enable the free standing nature ofthe insulated bag;

FIG. 5 is a perspective view of the inner plastic layer of FIG. 1 formedinto a pouch-like structure and showing a cuff thereof frictionallyengaging the upper ends of the intermediate foam insulating materialtherein;

FIG. 6 is a view similar to FIG. 1 showing one of the insulated bags ofthe invention with an opening and related closure for use in evacuatingand subsequently inflating the bag to permit compact storage andshipment to an end user;

FIG. 7 is a cross section taken along line 7-7 of FIG. 6 showing a tubeplaced through the opening for reducing the pressure within bag and theopen cell foam therein;

FIG. 8 is a perspective view of a plurality of insulated bags inaccordance with the invention being placed within an outer plasticsealable enclosure for shipment to an end user while compactly retainedor folded under internal reduced pressure;

FIG. 9 is a cross sectional view similar to FIG. 2 showing an alternateembodiment of the invention; and

FIG. 9A is the cross section view of FIG. 9 showing the alternateembodiment of the insulated shipping and storage bag in a free standingconfiguration.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With continued reference to the drawings, the invention will bedescribed with respect to several embodiments for insulated and flexibleor pliable hot/cold storage and shipping bags. A first embodiment ofinsulated bag 10 in accordance with the invention is shown in FIGS. 1-4.The insulated bag 10 is a multi-layer structure for storing and shippingtemperature sensitive items that is made of at least three layers ofthermal insulating materials. An outer layer 11 is made of materialsknown for reflecting radiant heat, are tear resistant, non-porous, leakproof, that can be heat sealed or otherwise welded or sealed with asterile poly pouch material and that is compatible with conventionalprinting techniques. Such materials include, but are not limited to,thermoplastic polymers, such as metallic polyethylene terephthalate(METPET), and various metallic foils. As noted, the outer layer 11 canhe printed with advertising information or any other indicia as desired.

The outer layer is formed of the above identified materials and isgenerally rectangular in shape when laid out in a one piece film. Theouter layer is preformed into a pouch or bag shape by folding the onepiece film along a midline thereof to create a bottom portion 12 withthe side edges thereof being welded, heat sealed or otherwise sealed toform opposite side seams 13 thereby creating an opening 14 into theouter layer.

An intermediate insulating layer 20, see FIG. 2, is constructed ofmaterials known for having low thermal transfers. Such materials includebut are not limited to low density collapsible open cell polyurethanefoams, including those foams that exhibit memory to reshape themselvesafter being deformed. Thus, the insulating layer is made of acollapsible or compressible, memory foam with thermal and cushioningproperties. The foam can be die-cast (molded) or cut and shaped toprevent any thermal bridges.

Thermal bridges are created when poorly insulated materials are used andallow heat transfer to occur through the material. To prevent thermalbridges, the insulated foam materials must be properly designed andplaced to properly insulate the area of concern in which an item to becontained within the insulated bag is to be received. In view of this,the insulating foam layer 20 is made from a polyurethane orpolyurethane-like foam to prevent thermal bridges and to effectivelymaintain the low thermal transfer needed to assure that any perishableproduct is maintained at optimal temperatures. In addition to the lowthermal properties of the foam, the foam is able to conform to any itemenclosed and to thereby become the frame and/or structure of the item.The self-forming foam creates a base or floor, lid and walls for aproduct when the product is placed therein. The foam also provides aprotective cushion for any articles placed within the bags and thusprotects against article damage.

With reference to FIG. 4, the foam insulating layer 20 may be betweenapproximately one half inch to one and one half inches in thickness andmay be of varying densities. The foam layer is form of a sheet that isgenerally rectangular in shape with two ends 21 and 22 beingsubstantially parallel to each other and two long sides 23 and 24 beingsubstantially parallel to each other. The insulating layer has, in eachcorner, generally rectangular cutout regions 25. Each cutout is definedby two intersecting wall portions 26 and 27 that intersect generallyperpendicularly with one another. The cutout regions 25 may include anadditional slit 25′ extending into the width of the material tofacilitate bending. The size of the cut outs 25 may vary depending uponthe size of the insulated bag with the function of the cut outs topermit the top of the completed bag to fold at the corners thereof whenthe layer 20 is folded centrally thereof at A-A to create opposing sidewalls 28 and 29, see FIG. 5. In addition to the corner cut outs,opposing cut outs 30 are provided centrally of the sides of theintermediate foam layer. The cut outs 30 are rectilinear and their sizemay also vary, it being the function of these cut outs to facilitate thefolding of the bottom 12 of a complete insulated bag to form a generallyflat support base for the bag when an item is placed therein and the bagis placed on a support surface “S”, as is shown in FIG. 3. As with theother cutout regions 25 the cutout regions 30 may include additionalslits 30′ extending into the width of the material to facilitatebending.

The insulated bag 10 also includes an innermost plastic layer 32 that ismade of one or more materials known for lower thermal convection. Suchmaterials include polyurethanes, polypropylenes, elastomeric compoundsand like materials that are leak-proof, non-porous and food grade andthat can be heat sealed or otherwise secured or welded to the outerreflective layer 11.

In the preferred embodiment of the invention shown in FIG. 1, the innerplastic layer 32 is formed as a bag or pouch that is only open at a topopening 34 thereof, as is shown in FIG. 2. The pouch is provided with anannular outwardly folded cuff 35 at the opening therein such that thecuff is of a size to frictionally receive and retain upper free endportions 36 and 37 of the opposing side walls 28 and 29 of theintermediate insulated foam. In this manner, the intermediate insulationmaterial is mechanically secured to the inner plastic layer 32 such thatboth layers may be simultaneously inserted within the outer reflectiveor metallic foil layer. This frictional retention of the intermediatelayer within the cuff of the inner plastic layer will also function toretain the intermediate insulating layer in place within the outer layerwhen the composite insulating bags of the invention are in use and willalso substantially seal the inner volume 40 of the insulated bag 10 fromthe volume or area 38 between the inner layer 32 and the outer layer 11to thereby prevent contamination of the inner volume 40. In someinstances an adhesive or other agent may be used to completely orhermetically seal the upper portions 36 and 37 of the intermediate foammaterial within the cuff 35 of the inner layer 32.

In some embodiments and as shown in FIG. 2, the upper end of the innerplastic pouch layer 32 is welded at 41 to the inner surface 42 of theouter layer, at or spaced slightly below the upper edges of the outerlayer to hermetically enclose the insulated bag 10 between the innerlayer 32 and the outer layer 11.

Although not shown in the drawings, in some embodiments, the innerplastic pouch-like structures of the inner layers 32 may be heat sealedat their upper open ends 44 after articles or items are placed with theinsulated bags 10. In other embodiments, mechanical zip-like closures ordouble sided tapes may be used to seal the upper ends 44 of the innerplastic bags after articles or items are placed therein. In yet otherembodiments, the inner plastic bags may not be sealed at the opening 34.

Preferably, the upper ends of the outer reflective or foil bag-likelayers 11 are provided with either heat seals or mechanical zip-likelocks or friction lock seals. In some embodiments, the seals may becreated using friction lock members 50 and 51 that are initially sealedat 52 to the upper edges of the opposing sides of the outer foil orreflective layers. Friction lock member 50 includes a handle 53 that isinsertable through an opening 55 in the lock member 51. Lock member 51is generally unshaped in cross section, see FIG. 2, with a width of thecross section being such that lock member 50 is frictionally seatedtherein to seal the members together when the handle 53 is insertedthrough the opening 55 to thereby seal the bag 10, see FIG. 3.

The insulated bag 10 can be closed using other known conventionalmethods such as pressure closures, taping closures, flaps withre-sealable taping means, flaps with peel-off taping means, plasticzip-lock fasteners and the like.

Although not shown in the drawing figures, in some embodiments one ormore addition foam layers may be inserted between the inner pouch orlayer 32 and the outer layer 11 to increase the insulating properties ofthe insulated bags to increase the length of time products will remainat optimal temperatures.

As previously described, one of the advantages of the present inventionis that the insulated bags may be compactly arranged and retained eitherfor storage or shipment to wholesalers or end users to thereby reduceshipping package volumes and thus reducing costs associated withshipping and storage of the bags. With reference to FIG. 8, a firstembodiment for reducing the volume of a package of the insulated bags 10of the invention is shown in detail. As shown, one or more insulatedbags 10 may be placed within an outer plastic bag 60 have one end with asealable opening 62. Thereafter, the outer bag is mechanicallycollapsed, as reflected by the arrow 65, to force most air out of theenclosed insulated shipping bags 10 and the outer bag 60. Thereafter,the outer bag is sealed. In some embodiments, a partial vacuum may beapplied within the outer bag to reduce the pressure therein and toreduce the volume of the overall package and the outer bag 60subsequently sealed.

In another embodiment of the invention and with reference to FIGS. 6 and7, to facilitate the compact handling and/or folding of themulti-layered insulated shipping and storage bags of the invention forstorage or shipment to wholesalers or end users for subsequent use, theinterior of the bags 10, and especially the intermediate open cell foamlayers 20 are designed to be evacuated by the application of a partialvacuum. Such a vacuum may be applied to the bags through openings 70between the outer reflective layer 11 and the intermediate open cellfoam material 20 thereof by use of a vacuum tube 72 or by placing thebags 10 within an enclosure under a reduced atmosphere. When the vacuumtube is withdrawn, or the predetermined reduced pressure is obtainedwithin the bags, the outer openings 70 therein are closed by removableadhesive patches or covers 74 to prevent ambient air from entering thebags. The covers or patches include a self stick adhesive 75 on theinner face thereof for use in sealing the openings to preventinadvertent inflation of the spaces within the bags. When the bags havebeen at least partially evacuated so that air is removed from the opencell foam and from between the outer reflective layer and the innerplastic layer or pouch 32, they are easily stacked or folded intocompact configurations for storage or for shipment. When the bags are tobe used by an end user, the patches or covers are removed and the bagswill automatically expand as ambient air enters the vacuum openingstherein. After the bags are inflated, the adhesive patches or covers maybe reapplied to prevent contaminants from entering the openings therein.In this regard, when the insulated shipping and storage bags 10 are tobe used to ship or store items that must remain sterile, the vacuumprocesses and inflating processes may take place within sterileenclosures.

With reference to FIG. 9, another embodiment or insulated bag 10′ of theinvention is disclosed wherein the cuff of the inner layer or pouch 32associated with the embodiment shown in FIGS. 1 and 2 is not used. Inthis embodiment, the inner layer or pouch 32′ includes an upper freeedge 76 that is directly sealed or welded at 78 to the inner surface ofthe outer reflective layer 11′ below the opening into the bag 10′. Thebag of this embodiment may be used with the vacuum opening and sealsassociated therewith as previously described and the materials and themanner of compact shipment or storage including the use of an outerpackaging container or pouch may also be the same.

We claim:
 1. An insulated shipping and/or storage bag having a bottom,walls, and an opening generally opposite the bottom, wherein the bag isconfigurable between a bag configuration and a free standingconfiguration capable of maintaining a supporting shape when placed on asurface, the bag comprising: an outer layer; an intermediate foammaterial layer, said intermediate foam material layer being made from asingle sheet of material having a generally rectangular shape with cutouts at each of four corners thereof and opposing cut outs generallycentrally along opposite side edges of said sheet of material so as toform a middle portion between two side portions each having an endportion on an end opposite said middle portion, said cut outs enabling afree standing configuration whereby said intermediate foam materiallayer is folded centrally thereof so that said middle portion becomesthe bottom, said side portions become the walls, and said end portionscover the opening of the bag and whereby said intermediate layercontinuously extends along the bottom and walls and covers the openingof the free-standing configuration of the bag without overlap of saidintermediate foam material layer; and an inner plastic layer that isconfigured to form an article receiving pouch, said inner plastic layerincluding a cuff in which said end portions of said intermediate foammaterial layer are received to thereby secure said intermediate foammaterial layer to said inner plastic layer and to create a sealseparating said intermediate foam material layer from the interior ofthe bag, wherein in the free standing configuration of the bag, saidcuff extends over said end portions and along at least a portion of anouter surface of said intermediate foam material layer.
 2. The insulatedshipping and/or storage bag of claim 1 further comprising venting meansto vent air from between said inner plastic layer and said outer layerto permit the shipping and/or storage bag to be compactly configured forshipment to an end user without allowing air to enter the interior ofthe bag.
 3. The insulated shipping and/or storage bag of claim 2 furthercomprising covering means for covering said venting means.
 4. Theinsulated shipping and/or storage bag of claim 1 wherein saidintermediate layer is between approximately one half inch to one and onehalf inches in thickness.
 5. The insulated shipping and/or storage bagof claim 1 wherein said sheet of material further includes slitsextending inwardly from each of said cut outs.
 6. The insulated shippingand/or storage bag of claim 1 wherein said inner layer is secured to aninner surface of said outer layer adjacent the opening into the bag. 7.The insulated shipping and/or storage bag of claim 1 further comprisingsealing means for sealing the opening into the bag.
 8. The insulatedshipping and/or storage bag of claim 7, wherein said sealing meansincludes a handle.
 9. The insulated shipping and/or storage bag of claim1, wherein said intermediate layer is substantially formed of an opencell foam.
 10. The insulated shipping and/or storage bag of claim 1,wherein said outer layer is a radiant energy reflecting layer.
 11. Theinsulated shipping and/or storage bag of claim 1, wherein a portion ofsaid cuff extending along at least a portion of an outer surface of saidintermediate foam material layer is secured to an inner surface of saidouter layer of the bag.